Tyre Size

:245/65 R16 Elanzo Supra TL

Customer

:Mahindra & Mahindra

Problem Description

:Cut Mark On the Tread End

Quantity Reported

:18 Tyres with week code 4013/4213

Complaint Receipt date

:21.10.2013 Through Mail

1

ERA/ICA(Containment Action)

1)On receipt of the complaint, Screening has been started at Mahindra and defect free tyres are feed to the Line .-1500 tyres 2)Screening at JK Tyres ,Chennai Plant started- 809 tyres 3)All the concerned operatives and others were well informed about the issue and high level of awareness was created.

Problem Description: Tyres are identified with Trim knife cut mark on the tread portion at Mahindra Customer assembly line. Defect is shown below in the image

Defect Tyre Images

Process Flow of Tyre Manufacturing

Mixing

Static Balancing

Stock preparation

Dynamic Balancing

Tyre Building
Tyre Curing

100% QA Visual Inspection

Warehousing

Defect occurring process Defect passing process

Trimming First Line Inspection by Production Operatives

Uniformity Testing Dock Audit Before vehicle loading for OEM dispatch

Cured Tyre Before Trimming

Vents to be trimmed

As cured

As cured

Process and Images-Tyre Vent Trimming

Trimming M/C front side

Tyre Entering to M/C

Trimming

Trimming Knifes

Radial Blade

Lateral Blade
6

Cause and Effect

Flash Trimming Knife cut damage

Man

Machine

Missed to identify damage in First Line and Second Line Fire wall

Tire Holder Damage in Trimming

Lateral Blade position incorrect

Cut Mark On Tread

Material Lightness

Method

Material

Cause Validation and Analysis

4M Cause Validation Decision (Significant/Non significant) significant

Man

Missed to identify damage in First Line and Second Line Fire wall Flash Trimming Knife cut damage Tire Holder Damage in Trimming Lateral Blade position incorrect Material Lightness

Checked in the Finished Good and tyres are identified Not possible by Flash removing knife .Flash is in the mid of the sidewall circumference Holder surface is smooth and no such issue Simulated and found the cut mark

Man

Insignificant

Machine

Insignificant

Machine

Significant

Material

No such defect in this tyre size from the start of the production itself and the defect records of Oct 13&Sep 13 also reveals the same

Insignificant

Root Cause Analysis Cause Knife Cut mark on tire

Why

Why-Why Analysis

Lateral Trimming Blade Position incorrect (excess forwarding which caused tire damage)
Why

Height/Time setting is same as that of other small tires(12 inch to 15 inch)

Why

End effect was not known and the setting was common for all tires

Root Cause

Tyre specific height/Time setting not carried in PLC

Counter Measure

Tire specific Height and Time setting Carried in M/C to tire specific

Blade Actual posi

Blade Required Po

Root Cause Analysis Cause Missed to identify damage in First Line and Second Line Fire wall
Why

Why-Why Analysis

Passed to next process due to operator negligence

Root Cause

Passed to next process due to operator negligence

Counter Measure

All the persons involved were counselled and high level of alert was created in CTP

10

Corrective Action Summary

4M Cause Countermeasure Status

Man

Missed to identify damage in First Line and Second Line Fire wall

Awareness created and the tyres are ensured with no such cut marks

Completed on 21.10.2013

Machine

Tyre specific height/Time setting not carried in PLC

Height and Time setting carried to tire specific. The same will be ensured in weekly check by maintenance

Completed on 21.10.2013

11

3 Levels Of Inspection

First Line Inspection-Production

Second Line Inspection-QA

Dock Inspection-QA

12

Conclusion :

JK will ensure the defect free dispatch to M&M by maintaining the tyre specific heights/time setting in PLC and strengthening the Inspection at three levels(First Line Inspection by Production/Second Line Inspection by Quality and Final Dock Inspection by Quality)
JKTIL (CTP) will continue to ensure the above points to ensure there is no customer line hindrances henceforth.

13